DS 19 OPERATION No. DS 330-3 : Overhauling a gearbox. Op. DS 330-3 201
TOOLS
Assembly.
23 To assemble the clutch housing (see Pl. 58)
a) Fit the thrust race support hub (76) (spring washers under the heads of the screws, previously smeared with
Hermetic, see Pl. 52). Insert a joint smeared with Hermetic. Fit the thrust guide screw (74) with its locknut
(shake-proof washer under the nut).
Adjust the position of the screw, so that its end is set at a dimension “b” 97 ± 1 mm from the face of the joint
with the engine.
Tighten the locknut.
To fit the clutch fork :
Engage the previously oiled shaft in the right-hand bore, offer up the fork fitted with its return springs.
Cars produced before June 1959.
Tighten the screw (75) locking the shaft (plain washer under the head) and tighten the locknut.
Cars produced since June 1959 (see fig. 3).
Fit the two circlips retaining the spindle (77).
Put the thrust bearing in position, fix it in position by means of the retaining springs (73) . . . . . . . . . . . . . . . . 8-12mm box spanner
14 mm ring spanner
NOTE - Do not refit the oil tube if one was found when dismantling.
b) To fit the pulley driving shaft:
Put in position, the bearing (71) previously greased in the bore of the bellhousing. Tighten the nut (70)
(spanner 1640-T, see Pl. 63, fig. 5), split pin. Fit the oil retaining washer (72) on the shaft and insert the
assembly in the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spanner 1640-T
c) Adjust the alignment of the pulley (see Op. DS 231-0).
24 To assemble the cover plate (see Pl. 55):
a) To check the selector fork return springs: under a load of 54 to 56 lbs (24.5 to 26kg), the length should be 68 mm.
(Fixture for calibrating the springs 2420-T, see Pl. 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixture for calibration
2420-T
b) To fit the selector forks :
Fit the 1st and 2nd speed selector shaft (77) through the rear of the cover plate. Fit the return spring without
the cups, then selector fork (78) (spring compressor 1798-T, see Pl. 56, fig. 1).
Insert the selector shaft locking plunger (66).
Fit the reverse selector shaft (79), its return spring and the selector fork (80).
Insert the 3rd and 4th speed selector shaft (61), its return spring, fit the selector shaft plungers (66), the
rocker (63), the 3rd and 4th speed selector fork (64).
Tighten the locking screws on the selector forks. Lock the screws with iron wire, fitted so as to prevent any 7-8 mm spanners
rotation in the direction of unscrewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring compressor
1793-T
25 To prepare the differential (see Pl. 54, fig. 1):
a) Fit the taper roller bearing (mandrel 1768-T, see Pl. 61, fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mandrel 1768-T
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